Gas scrubber apparatus and method for use thereof

ABSTRACT

A gas scrubber for the effluent from smokestacks is widely distributed and intermixed with a water vapor mist followed by agitation through ingenious watery beaters so that the water captures the solid particle constituents and captures the materials soluble in the water. The water after settling the particles therefrom may be recycled.

1 United States Patent 1151 3,637,192 Giconi 1451 Jan. 25, 1972 GAS SCRUBBER APPARATUS AND 1,103, 4 7/1 14 METHOD FOR USE THEREOF 1,112,860 10/1914 3,139,331 6/1964 [72] Inventor: Renell A. Giconi, 12 Park Drive, La Vale, 3,179,387 4/1965 Md. 21502 Primary Examiner-Tim R. Miles [22] Flled' 1970 Assistant Examiner-Steven H. Markowitz {21] Appl.NO.: 63,414 Attorney-Schellin and Hoffman [52] U.S.Cl ..26l/l7,261/2l,261/89, [57] ABSTRACT 261/1 18, 55/228 A gas scrubber for the effluent from smokestacks is widely dis- [51] Int. Cl ..B01d 47/06 tri an in ermix d with a water v p r mi follo e y [58] Field of Search ..261/ 16, 17, 21, 89, 117, 118 agitation through ingenious watery heaters so that the water captures the solid particle constituents and captures the [56] References Cited materials soluble in the water. The water after settling the particles therefrom may be recycled. UNITED STATES PATENTS 1,083,068 12/1913 Egler ..261/89 14 Claims 4 Dmwmg SMOKE PATENTED M25197? WWW H E? SMOKE ATTORNEYS GAS SCRUBBER APPARATUS AND METHOD FOR USE THEREOF BACKGROUND OF THE INVENTION It will be appreciated that considerable activity has been undertaken through a great number of years with respect to the concept of removing undesirable constituents from the gas and smoke resulting from the combustion of fossil fuels and from the smoke and gases emanating from, for instance, smelter operations. All of the prior art devices which have been disclosed have a certain degree of efficiency. One of the great problems attendant the cleaning or scrubbing of the smoke emanating from various sources resides in the fact that such gases and smoke accumulate extremely rapidly from the larger and larger facility being constructed in modern America. Additionally, the gaseous stream of byproducts resulting from such constructions now produces greater quantities of undesirable constituents as lower grades of ores, coal and oil are being employed. Consequently, the gas scrubbers of the prior art are not as efficient or as easy to run as must be expected.

SUMMARY OF THE INVENTION The present invention contemplates an apparatus which successfully scrubs a gaseous smoke stream emanating from a smoke wherein the gaseous stream has an initial temperature gradient of approximately 1,500 F. The gaseous stream is led into a first chamber in which the stream is cooled somewhat from the very high temperatures of introduction. Further cooling gas as an impingement fluid is provided by means of a plurality of fans which carry forward much of the impure gas and reduces its initial high-temperature gradient. It has been found that by impinging the introduced air atan acute angle with respect to the flow of the gas that a high degree of turbulence and heat exchange is obtainable thereby. From the initial distribution and cooling chamber, the gases are conveyed to a second chamber, usually, located thereabove. Within the second chamber a plurality of water mist producing means are located in order to further cool the gaseous stream and at the same time encapsulate in the produced droplets of water the solid constituents of the smoke as well as to solubilize those gases soluble therein such as sulfur dioxide and ammonia. The residence time in this second chamberis somewhat longer than the residence time in the first chamber so that it must be constructed of a larger dimension.

The gas stream is then conveyed to a third treatment chamber and is introduced near the top thereof. Additional water is sprayed to the upper reaches of the chamber and is distributed by means of a plate having many holes therein. A beater arrangement which is suitably motorized insures a good mixture between the gases and the spray. The chamber is divided into a double unit so that the second unit below the first is the same and undertakes a further distribution. The smoke that has now been thoroughly cleaned is led from the bottom of the chamber and may be discharged tothe atmosphere unless additional treatment is required.

The water and condensation materials are picked up by gravity flow from the bottom portions of each of the three chambers and are pumped to settling tanks from which the stratified cleared water may be utilized in a recycling technique.

DETAILED DESCRIPTION OF THE INVENTION Before undertaking a detailed consideration of the inventive concept underlying the present invention, attention is directed to the drawings:

FIG. 1 is a stylized schematic perspective view of the various chambers in the instant invention.

FIG. 2 is a top plan view of the chamber for distributing the gas stream.

FIG. 3 is a cross-sectional view of the settling tank.

FIG. 4 is a cross-sectional view of all of the chambers showing the relative positions thereof and internal construction.

The smoke at a temperature of approximately l,500 F. is permitted to rise up a conventional stack shown by reference numeral 11 in FIG. l. The smoke is then carried downwardly along conduit 12 to first-treatment chamber 13 in which the smoke is initially cooled and the gross particles may be removed therefrom as any water vapor in the smoke is condensed and accumulates in the bottom. Just prior to the entrance of conduit 12 into first-treatment chamber 13, steam is introduced into the moving stream at conduit 12A. The introduction is accomplished at an acute angle with respect to the smoke to assist it; driving it into chamber 13. Such liquid and particles are then removed from first chamber 13 by means of conduit 14. The smoke then rises to another chamber through a conveyor tube 15 to a second chamber 16 in which the smoke is given a water mist treatment for further cooling and precipitation of particle constituents from the smoke. Thereafter, the liquid that accumulates in the bottom of second chamber 16 is removed through conduit I7 to a gathering line 18 which carries the liquid containing the particle constituents to a settling tank 19. After treatment in second chamber 16 the smoke that has been partially scrubbed and is partially cleared of particle constituents is carried by means of conduit 9 to a third-treatment chamber 20. The partially scrubbed smoke is introduced at the upper portion of the chamber along with quantities of water introduced by conduit 21. Again, the liquid containing the water and additional particles are removed from chamber 20 at the bottom thereof through conduit 22 for connection to gathering line 18 which, as stated in the above, makes a connection with the settling tank 19. The gas which has now been cooled to ambient conditions is discharged through conduit 23 either to the atmosphere or for further treatment as needed.

For a more detailed considerationof the arrangement set forth in the various chambers, attentionis directed to FIG. 4.

As stated in the above, the hot smoke rises in stack 11 and is then turned downwardly in conduit 12. The flow reversal is accelerated by means of an electrically driven fan 31 which is directed downwardly and introduces cooling air as well as giving impetus to the moving stream. Further impetus is given by. means of subsequent electric blowers 32 and 33. These blowers provide impetus as well as additional cooling air for lowering the temperature from the initial high-temperature range. Blowers 32 and 33 are positioned at an acuteangle with respect to the moving stream of smoke in conduit 12. The moving stream of smoke along with the newly introduced air is carried through the bottom portion of first-treatment chamber 13 and is then carried through a manifold distributingmeans 34 which is displaced from the walls of the first-treatment chamber 13. For a more detailed consideration of the inside construction of first-treatment chamber 13, attention is directed to FIG. 2. However, the first-treatment chamber of FIG. 2 is a slightly different embodiment in that the manifold distribution system 34 is in a series of vertically disposed conduits 35 with a number of outlets 36 located along each vertically disposed conduit 35. In the embodiment shown in FIG. 4 the conduits 35 are horizontally disposed. Nevertheless, the result is the same. Returning to FIG. 4, the reason the manifold 34 is spaced from the bottom of first-treatment chamber 13 is to provide an area for accumulation of fluids condensed from the smoke stream as the smoke is cooled and to provide an accumulation zone for such liquid which is then discharged through conduit 14 towards the settling tank 19. It will be noted from FIG. 4 that additional booster fans 37 and 38 are located at the side corners of the uppermost portions of first-treatment chamber 13 in order to further cool the smoke and to provide additional driving force so that the smoke is now directed upwardly through conveyor tube 15. This tube communicates between chamber 13 and second chamber 16. The tube 15 terminates at a position above the bottom of second chamber 16. A centrally located baffle arrangement 39 directs the smoke in a more horizontally disposed direction and somewhat downwardly. Skirt 39A provides for a downward deflection. Again, by considering the terminus of tube above the bottom of second chamber 16 an area is provided for accumulation of liquid constituents which is discharged through conduit 17 in a direction towards the settling tank 19 as mentioned heretofore. The horizontally directed gas stream is then distributed by natural flowing gravitational means so that portions of the gas underlie the first annular baffle 40 of second chamber 16. It will be noted that there are two additional vertically displaced annular baffles 41 and 42. Between baffles 40 and 41 are a plurality of nozzles 43 for injection in a spray fashion of a stream of water. Part of the water impinges against the underside of annular baffle 41 and is deflected therefrom in a direction towards the axis of second chamber 16. Likewise, water nozzles are provided between baffles 41 and 42 as identified by reference numeral' 44. Finally, a third set of water spray nozzles 45 are located above annular baffle 42 and below the roof 46 of the second chamber 16. The baffles 40, 41 and 42 are arranged to be at a small acute angle with respect to a perpendicular line to the axis of second chamber 16. Suitable holes as, for example, 47 are located at the end of the baffles which connect with the annular sidewall of the second chamber 16 so that water accumulation may drip and flow downwardly for accumulation in the bottom of second chamber 16 for ultimate removal as described before.

The fan blowing means as described in the above are utilized to drive the smoke forward while the spray nozzles carrying the water are designed to move the smoke in the opposite direction. Consequently, the gravitational fall of the water particles will effectively encapsulate the solid constituents in the smoke for removal by conduit 17 as described before. A centrally located discharge conduit 9 is positioned in the roof 46 of second chamber 16 for a secondary cleaning step in the third chamber identified by reference numeral 20.

It will be seen that conduit 9 carries the relatively clean gas upwardly for introduction into the third chamber at the upper portion thereof. Simultaneously with the introduction of the gaseous stream from conduit 9 water is sprayed therein as by nozzle 50. The water accumulation is of such a rate that a slight shallowness of water accumulates above perforated plate 51 which is adjusted so that there is always a relatively thick film of water over the entire plate and then as the water drips downwardly through the openings in the plate the dropping motion produces a sucking vortex in each perforation in order to carry with it the gas from conduit 9.

Below the perforated plate 51 is a driven rotatable beater 53 which is keyed to shaft 54. Driving motion to shaft 54 is given by electromotive means 55 located above the third chamber 20. An annularly disposed baffle arrangement 56 is positioned to demark the first section of third chamber 20. The drive shaft 54 projects therethrough downwardly and terminates in a second beater 57. The falling water and accumulated gas are driven downwardly into the lower reaches of third chamber through opening 58. The water and gas again accumulate on a perforated plate 59 and then drop downwardly through the openings therein in the same manner as before as the openings are of about the same size. The heaters 53 and 57 are designed to vigorously mix the water and the gaseous stream and to hurl the materials against the annular sidewall of third chamber 20. Again, the second portion of third chamber 20 terminates in an annular baffle arrangement 60 with a centrally located opening 61. It will be noted that the baffle arrangement 56 and baffle arrangement 60 have sloping upper surfaces so that the water and gases are distributed radially towards the central openings 58 and 61 respectively. The annular baffle arrangement 60 is vertically displaced from the bottom of third chamber 20 to provide a zone for accumulation of water and undesirable effluent which is then discharged through a line 22 in the direction of the settling tank 19. Any remaining gas which has not been solubilized in the water is then discharged through: line 23 to the'ambient or for further treatment as mentioned.

All of the effluent resulting from chamber 13, 16 and 20 are accumulated into gathering line 18 and are flowed into the bottom of settling tank 19. As can be seen from FIG. 4 and especially from FIG. 3, the settling tank is divided into three chambers 65, 66 and 67. A weir 68 separates chamber 65 from chamber 66 and a lower weir 69 separates chamber 66 from 67. The liquid from gathering line '18 is introduced near the bottom of the first chamber 65 and is permitted to fill that chamber at which point it overflows weir 68 to fill chamber 66 which when filled then overflows therefrom into chamber 67. A control switch 70 is set up as can be seen from FIGS. 4 and 3 to monitor the level of the water in chamber 67. As the chamber 67 is filled, water may be pumped directly from the settling tank 19 by means of line 72 to water storage 73. Horizontally disposed driven screws 71 in each of the chambers will carry forward and out of the settling tank 19 the solid accumulation. Suitable valving arrangement is in association with each of thescrews 71 but is not shown. Such valving arrangement would be necessary to prevent the continuous discharge of water from the settling tank. When the monitoring switch 70 indicates that the settling tank is full, then a second and tertiary settling tank (as tank 19) may be brought into operation while the stratified liquid from the first settling tank 19 is removed through conduit 72 for storage in tank 73. A water pump 74 is positioned at the terminus of the final-settling chamber 67 so that the water is pumped therefrom for recycling at various units as at second chamber 16 by means of another pump 75 and for further distribution in the direction of the third chamber 20.

Switch arrangement 70 consists primarily of a high-low switch so that when the water level in chamber 67 is too low, makeup water may be added as required and when the water level is too high, makeup water may not be required and may in fact require the stoppage of use of the first-settling tank 19 at that point so that another settling tank may be brought into play.

As was stated heretofore, considerable quantities of gases may be solubilized and entrapped in the fluid water which in the settling tanks may then accumulate over the surface of the water levels in settling tank 19. A vent 77 is provided for removal of such gases.

If the apparatus of the present invention is employed which utilizes as a source gases from a smelter then considerable quantities of sulfur dioxide will be obtained which to a great degree are soluble in the water. These gases may be exhausted from the vent 77 for use in the production of sulfuric acid.

One of the main benefits of the present invention obtainable therefrom is as a result of the use of concrete or plastic in most of the construction materials employed. It will be appreciated that concrete has a uniqueness in that it is impervious to hightemperature conditions and to high-acidic conditions. Consequently, the apparatus of the present invention may be constructed by concrete construction techniques and thereby employ a great deal of unskilled labor making for economic construction of the device of the present invention.

While there have been shown and described particular embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and, therefore, it is aimed to cover all such changes and modifications as fall within the true spirit and scope of the invention.

What is claimed is:

1. A method for scrubbing undesirable constituents from smoke producing by cornbusting fossil fuels or smelting ores comprising driving such smoke in a forward direction by forcibly introducing air at an acute angle into a stream of said smoke, driving said smoke into a first zone and subjecting said smoke therein to turbulent agitation with the concomitant introduction of additional air, conveying said smoke to a second zone and passing said smoke therethrough, introducing into said second zone a stream of finely divided water moving transversely with respect to said smoke stream, thereafter conveying said smoke into a third zone simultaneously with a stream of finely divided water and in the same direction, hurling said smoke and said finely divided water perpendicularly and outwardly, and accumulating the finely divided water and smoke and clarifying the accumulated water for recycle.

2. The method of claim 1 wherein the finely divided water in the second zone is also accumulated and clarified for recycling.

3. The method of claim 1 wherein the smoke being treated has an initial temperature of about l,500 F.

4. A gas scrubber apparatus comprising an introductory conduit for said gas, said conduit having at least one blower therealong for introducing air at an acute angle with respect to said gas, a first chamber, said conduit terminating in said chamber, a manifold in communication with said conduit, said manifold having a plurality of openings between it and said first chamber, blower means for introducing additional air into said first chamber, a second chamber, a conduit for said smoke communicating between the first chamber and said second chamber, said second chamber having water spray means for producing a countercurrently moving stream of finely divided water with respect to said smoke, a third chamber, a conduit for said smoke communicating between said second chamber and the top portion of said third chamber, means for introducing spray water into the top portion of said third chamber, drip plate means positioned below the point of introduction of said smoke and sprayed water into the third chamber, agitation means below said drip plate means for hurling the smoke and water against the side of said third chamber, means in said third chamber for separately removing said scrubbed smoke and said water, means for clarifying said water for recycle.

5. The gas scrubber of claim 4 wherein a second drip plate means in positioned below the agitation means and a second agitation means is positioned therebelow.

6. The gas scrubber of claim 4 including a settling tank as the means for clarifying.

7. The gas scrubber of claim 4 wherein the second chamber contains a series of vertically displaced annular baffies with spray means positioned therebetween.

8. The gas scrubber of claim 7 wherein the baffies are at acute angles to the horizontal sloping downwardly from their axis thereof.

9. The gas scrubber of claim 8 wherein a centrally positioned plate is vertically displaced over the end of the conduit for said smoke which communicates between the first chamber and the second chamber.

10. The gas scrubber of claim 9 wherein the plate has a depending skirt for deflecting the smoke entering the second chamber,

11. The gas scrubber of claim 6 wherein the settling tank is divided into three sections and overflow weirs are provided therebetween.

12. The gas scrubber of claim 11 wherein each of the sections of the settling tank possesses a horizontally disposed means at the bottom thereof for removing solid particle accumulation.

13. The method of claim 1 wherein steam is introduced into said stream at a point prior to introducing the stream into the first zone so that the stream is driven.

14. The gas scrubber apparatus of claim 4 wherein the conduit for said gas is provided with a means for introducing steam at an acute angle whereby the stream is driven. 

2. The method of claim 1 wherein the finely divided water in the second zone is also accumulated and clarified for recycling.
 3. The method of claim 1 wherein the smoke being treated has an initial temperature of about 1,500* F.
 4. A gas scrubber apparatus comprising an introductory conduit for said gas, said conduit having at least one blower therealong for introducing air at an acute angle with respect to said gas, a first chamber, said conduit terminating in said chamber, a manifold in communication with said conduit, said manifold having a plurality of openings between it and said first chamber, blower means for introducing additional air into said first chamber, a second chamber, a conduit for said smoke communicating between the first chamber and said second chamber, said second chamber having water spray means for producing a countercurrently moving stream of finely divided water with respect to said smoke, a third chamber, a conduit for said smoke communicating between said second chamber and the top portion of said third chamber, means for introducing spray water into the top portion of said third chamber, drip plate means positioned below the point of introduction of said smoke and sprayed water into the third chamber, agitation means below said drip plate means for hurling the smoke and water against the side of said third chamber, means in said third chamber for separately removing said scrubbed smoke and said water, means for clarifying said water for recycle.
 5. The gas scrubber of claim 4 wherein a second drip plate means in positioned below the agitation means and a second agitation means is positioned therebelow.
 6. The gas scrubber of claim 4 including a settling tank as the means for clarifying.
 7. The gas scrubber of claim 4 wherein the second chamber contains a series of vertically displaced annular baffles with spray means positioned therebetween.
 8. The gas scrubber of claim 7 wherein the baffles are at acute angles to the horizontal sloping downwardly from their axis thereof.
 9. The gas scrubber of claim 8 wherein a centrally positioned plate is vertically displaced over the end of the conduit for said smoke which communiCates between the first chamber and the second chamber.
 10. The gas scrubber of claim 9 wherein the plate has a depending skirt for deflecting the smoke entering the second chamber.
 11. The gas scrubber of claim 6 wherein the settling tank is divided into three sections and overflow weirs are provided therebetween.
 12. The gas scrubber of claim 11 wherein each of the sections of the settling tank possesses a horizontally disposed means at the bottom thereof for removing solid particle accumulation.
 13. The method of claim 1 wherein steam is introduced into said stream at a point prior to introducing the stream into the first zone so that the stream is driven.
 14. The gas scrubber apparatus of claim 4 wherein the conduit for said gas is provided with a means for introducing steam at an acute angle whereby the stream is driven. 